JPH10305526A - Decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a fire retardant decorative panel or an incombustible decorative panel which can be approved as an incombustible material according to the notice No. 1828 of the Ministry of Construction. SOLUTION: Two or more layers of core-material layer sheet materials 5 in which a glass fiber non-woven fabric is coated with compounded material composed of melamine resin and aluminum hydroxide, the composition ratio between the melamine resin and aluminum hydroxide being (3-15 wt.%):(97-85) wt.%, a reinforcing-layer sheet material 6 in which a glass fiber woven fabric is coated with thermosetting resin and which is interposed between the materials 5, and decorative-layer sheet materials 2, 3 superposed on the surfaces of the materials 5 are stacked one on another to form these materials into a single body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant or non-combustible decorative board mainly used as an interior material for various uses.

[0002]

2. Description of the Related Art A conventional flame-retardant or non-flammable decorative board has processability,
Many inorganic materials are problematic in terms of impact resistance or safety to the human body due to the inclusion of asbestos. On the other hand, organic resin-based decorative boards are disclosed in JP-A-1-56539 and JP-A-1-5-5.
Although it is disclosed in Japanese Patent No. 6540 and the like, heat generation and smoke generation during combustion are remarkable, and shape retention after a combustion test (a surface combustion test and a base material combustion test according to the Ministry of Construction Notification No. 1828; hereinafter, referred to as a nonflammability test). It was difficult and could not obtain the reliability as a flame-retardant or non-flammable decorative board.

[0003]

SUMMARY OF THE INVENTION The present invention is to provide a flame-retardant or non-combustible decorative plate which is excellent in flame retardancy or non-flammability and has little dimensional change, warpage deformation and the like.

[0004]

According to the present invention, a glass fiber non-woven fabric is composed of a melamine resin and aluminum hydroxide in a composition ratio of 3 to 15% by weight to 97 to 85% by weight (non-volatile content ratio, hereinafter the same). )), And a thermosetting resin was applied to a glass fiber woven fabric inserted between two or more core material sheet materials coated with the composition and the core material sheet material. The present invention relates to a flame-retardant or non-combustible decorative plate, characterized in that a sheet material for a reinforcing layer and a sheet material for a decorative layer are superposed on the surface of the sheet material for the core layer, and are laminated and integrated.

[0005] In the present invention, the glass fiber non-woven fabric is preferably used for coating a composition comprising a melamine resin and aluminum hydroxide and impregnating the inside of the substrate, and in particular, has a basis weight of 30 to 150 g / m ^2. Are preferred. Because the basis weight of the glass fiber nonwoven fabric of insufficient strength is less than 30 g / m ^2, it may have difficulty in handling at the time of coating the formulation onto a glass fiber non-woven fabric, or molded or the like, 150 g / m ² If the ratio exceeds the above, the adhesion between the layers may be insufficient at the time of molding.

[0006] The composition comprising melamine resin and aluminum hydroxide is composed of 3 to 15% by weight of melamine resin and 97 to 85% by weight of aluminum hydroxide, so that the decorative board obtained has excellent flame retardancy. However, if the melamine resin content is 10% by weight or less, it conforms to Ministry of Construction Notification No. 1828, “Designating Noncombustible Materials”. If the melamine resin is less than 3% by weight, the melamine resin cannot sufficiently exhibit the function as a binder, so that there is a problem in handling the core material layer sheet material and in the interlayer strength after molding, which is not preferable.

This composition is used as it is or after being diluted with a diluent such as water or alcohol. In this composition, when the ratio of a diluent such as water and alcohol (including those originally contained in the resin) to the solid content is defined as the dilution ratio, the dilution ratio depends on the ratio of the resin in the formulation. , Usually about 0.05 to 0.5, preferably about 0.1 to 0.3. If it is smaller than this range, the viscosity of the composition is high, making it difficult to perform coating. If it is larger, the viscosity is low, and the coated composition is less likely to be held on the glass fiber nonwoven fabric. Next, if necessary, the diluted composition is applied to a glass fiber nonwoven fabric. Assuming that the ratio of the compound (solid content) to the glass fiber nonwoven fabric at the time of coating is the impregnation rate, the impregnation rate depends on the basis weight of the glass fiber nonwoven fabric,
Usually about 5 to 100 times by weight, preferably 10 to 60 times
About twice. If it is less than 5 times, it is difficult to maintain the required thickness and the surface finish may not be sufficient. Further, the flame resistance decreases and the cost increases. If it exceeds 100 times,
It has good flame resistance, but has drawbacks such as easy collapse during handling of the core layer sheet material.

The melamine resin generally has a molar ratio of formaldehyde to melamine (hereinafter simply referred to as a molar ratio) of 1.5 to 4.0, but is not limited to this range. It is preferably in the range of 1.5 to 3.0 from the viewpoints of fuming property, storage stability of the resin varnish, and the like, and an acidic curing agent can be appropriately compounded.

On the other hand, it is preferable that aluminum hydroxide having a large particle diameter and a particle having a small particle diameter are mixed and used, and the aluminum hydroxide is packed closest. When a material having a small particle size is used alone, the uniformity of the core material layer sheet material or the decorative plate can be ensured, but the workability at the time of mixing the mixture is difficult. When a material having a large particle size is used alone, it is difficult to handle the obtained core material layer sheet material, and at the same time, a decrease in nonflammability due to a decrease in the particle surface area is observed. The close-packing of aluminum hydroxide with different particle diameters improves the wettability of the compound when preparing the sheet material for the core layer, as well as the workability when mixing the compound, the handling of the sheet, and the incombustibility. Etc. are also favorable, which is preferable. As for this particle size, a large one has an average particle diameter of 100 to 200 μm,
20 μm is preferred. In order to increase the packing density, it is preferable that the distribution of both particle diameters is within a range of about ± 50% around the average particle diameter, and the ratio of both average particle diameters is 5 to 5.
About 200 is preferable.

Next, a sheet material for a reinforcing layer, which is a feature of the present invention with respect to the prior art, will be described. Glass fiber woven fabric thermosetting resin is used to obtain a sheet material for the impregnated reinforcing layer, those having a basis weight of 50 to 350 g / ^{m 2,} more preferably from 100 to 250 g / m ^2. The thermosetting resin is not particularly limited, such as a melamine resin and a phenol resin, but is preferably a melamine resin in terms of flame resistance. For the ratio of thermosetting resin to glass fiber woven fabric,
When this ratio is large, the adhesion to the core material sheet material is good, but the flame resistance is reduced. Conversely, when the ratio is small, the flame resistance is good, but the adhesion to the core material sheet material is good. And the reinforcing effect is reduced. Therefore, in order to obtain a reliable reinforcing effect and good flame resistance, the impregnation rate of the thermosetting resin is usually 20 to 1 with respect to 100 parts by weight of the glass fiber woven fabric.
It is 50 parts by weight, preferably 25 to 100 parts by weight. By inserting such a sheet material for a reinforcing layer between two or more sheet materials for a core material layer to obtain a decorative board, a dimensional change,
Less warpage, deformation, etc., good shape retention after combustion, and great improvement in flame resistance.

As the sheet material for the decorative layer to be superimposed on the surface of the sheet material for the core layer, a material obtained by impregnating a thermosetting resin into a fiber sheet substrate for the decorative layer is used, and preferably pulp, linter, synthetic resin is used. Melamine resin alone or 60-95% melamine resin on a sheet or paper having a basis weight of 40-150 g / m ² , made of fiber, glass fiber, etc. and optionally containing a pigment such as titanium oxide, Alternatively, an impregnated sheet or paper impregnated with a composition comprising 40 to 5% of magnesium hydroxide or silica is used. The impregnation rate of the melamine resin or compound is usually 80 to 300% by weight based on the sheet or paper. The melamine resin is prepared by adding a usual modifier (for example, glycols) to 0.1%.
What added 1-20% can also be used, and an acidic hardening agent can be mix | blended suitably.

The decorative layer sheet material is laminated and integrated as a decorative layer on the surface of the core material layer sheet material. The sheet material similar to the decorative layer sheet material is also provided on the back side to prevent warpage and the like. It is preferred to use It is desirable that the thickness is 0.5 mm or less and the amount of the organic matter is 300 g / m ² or less regardless of whether it is on one side or both sides.
Those exceeding this range make it difficult to pass the nonflammability test.
More preferably, the thickness is 0.2 mm or less, and the amount of organic matter is 150 g / m ² or less. Also, it may be difficult to pass the nonflammability test for a molded product having a total thickness of less than 3 mm.

[0013] The sheet material for the core layer prepared as described above is laminated on a plurality of sheets, and the sheet material for the decorative layer or its equivalent is laminated on the front surface or the front and back surfaces, and is heated and pressed to form the flame retardant of the present invention. Or a nonflammable decorative board is obtained. At the time of molding, a mirror-finished plate, an embossed plate, an embossed film, or the like is overlaid, and the surface is finished to a mirror finish, an emboss finish, or the like.

[0014]

The present invention will be specifically described below with reference to examples and comparative examples.

Example 1 A basis weight of 75 g / m ² and a specific gravity of 0.
Example 1 was mixed with 94 parts by weight of aluminum hydroxide (47 parts by weight of an average particle diameter of 150 μm and 47 parts by weight of an average particle diameter of 8 μm) to a glass fiber nonwoven fabric having an organic binder amount of 11 g at 23 g / cm ³ . 6 parts by weight (solid content) of the same melamine resin used in
The composition comprising 5 parts by weight was applied to obtain a core material sheet material (5) having an impregnation ratio of 20 times. Next, basis weight 210g / m
^2. A melamine resin containing the same curing agent as described above was applied to a glass woven fabric having an organic binder amount of 0.08% to obtain a sheet material (6) for a reinforcing layer having an impregnation ratio of 80%. Sheet material for reinforcing layer (5) One sheet material for reinforcing layer (6) was inserted between the second and third sheets of the four sheets. Next, a decorative base paper for decorative board having a basis weight of 80 g / m ² is impregnated with a melamine resin containing a curing agent to prepare a decorative layer sheet material (2) having an impregnation rate of 100%, and a basis weight of 60 g / m ^2. Was impregnated with the same melamine resin as above to prepare a decorative layer sheet material (3) having an impregnation rate of 115%. These decorative layer sheet materials (2) and (3) each have a thickness of 0.1 mm,
The organic matter amount is 130 g / m ² . The sheet material (2) and (3) for the decorative layer are laminated one by one on the front and back of the sheet material (5) for the core layer, and molded at 140 ° C. and 80 kg / cm ² for 20 minutes to obtain a thickness. A 3.3 mm non-combustible decorative plate (7) was obtained.

Comparative Example 1 A basis weight of 75 g / m ² and a specific gravity of 0.
An aluminum hydroxide 80 having an average particle diameter of 8 μm was added to a glass fiber nonwoven fabric having an organic binder amount of 23 g / cm ³ and an organic binder amount of 11%.
Parts by weight and the same melamine resin 2 used in Example 1
A composition comprising 0 parts by weight and 20 parts by weight of water and methanol is applied, and a sheet material for a core layer having an impregnation ratio of 20 times (8)
I got Four sheets of the core layer sheet material (8), Example 1
The decorative layer sheet material (2) and the decorative layer sheet material (3), which are the same as those described above, are stacked one by one on the front and back, and hot-pressed under the same conditions as in Example 1 to obtain a decorative plate having a thickness of 3.2 mm. (9) was obtained.

The characteristics of the non-combustible decorative panels (4) and (7) obtained in the above Examples and the decorative panel (9) obtained in Comparative Example were evaluated, and the results are shown below.

[0018]

[Table 1]

(Test method) Substrate combustion test: According to Ministry of Construction Notification No. 1828. Surface burning test: According to Ministry of Construction Notification No. 1828. Judgment 1 = Hazardous deformation in fire prevention, generation of gas extremely harmful in evacuation, etc. Judgment 2 = Melting over the entire thickness of the specimen, 10 minutes of the thickness of the crack reaching the back surface, where the width of the crack is the full thickness Judgment 3 = Existence of residual flame for 30 seconds or more after the end of heating, Judgment 4 = Exhaust temperature curve of the test specimen (refer to the curve shown by the recording thermometer specified in No. 2) The standard temperature curve (the curve obtained by adding 50 degrees to the exhaust gas temperature for each elapsed time after adjusting the heating furnace specified in No. 1-2 of the item 1, and connecting them together) , determined 5 = smoke factor per unit area was determined by the following equation C _a 3
0 or less, C _A = 24 log ₁₀ I ₀ / I In this equation, I ₀ and I represent the following numerical values, respectively. I ₀ : Light intensity at the start of heating test (unit lux) I: Minimum value of light intensity during heating test (unit lux)

[0020]

According to the present invention, there is provided a decorative board according to the present invention for two or more core layers in which a composition comprising a melamine resin and aluminum hydroxide is applied to a glass fiber non-woven fabric at a melamine resin content of 15% by weight or less. Insert a sheet material for reinforcing layer impregnated with thermosetting resin into glass fiber woven fabric between sheet materials,
Since the decorative layer or its equivalent is laminated and integrated on the surface or front and back of the core material sheet, the resulting decorative plate has small dimensional change, warpage, deformation, etc. The amount of generated heat and the amount of smoke are suppressed to a small amount, and shape destruction after combustion is small.

In particular, the above-mentioned glass fiber nonwoven fabric is coated with a composition comprising a melamine resin and aluminum hydroxide at a melamine resin content of 10% by weight or less, and the thickness or thickness of the core material layer sheet material is increased. When a decorative layer having a thickness of 0.5 mm or less and an organic content of 300 g / m ² or less or an equivalent thereof is laminated and integrated, the amount of heat generated during combustion and the amount of smoke generated are suppressed to an extremely small amount. It has almost no shape destruction after combustion and is certified as a non-combustible material conforming to Ministry of Construction Notification No. 1828. Further, since a decorative layer sheet material similar to a conventional decorative plate can be used for the decorative layer, the decorative layer can be freely selected from a wide variety of colors and patterns and used as a flame-retardant or non-flammable material for various uses.

[Brief description of the drawings]

FIG. 1 shows a sheet material for reinforcing layer (6) inserted between a sheet material for core layer (5), and a sheet material for decorative layer (2) and a sheet material for decorative layer on the front and back surfaces of the sheet material for core layer (5). Sectional drawing of the noncombustible decorative board (7) which carried out lamination molding of (3).

FIG. 2 is a sectional view of a decorative plate (9) in which decorative layer sheet materials (2) and (3) are laminated and formed on the front and back surfaces of a core material layer sheet material (8).

[Explanation of symbols]

 2,3 Sheet material for decorative layer 5 Sheet material for core layer 6 Sheet material for reinforcing layer 7 Non-combustible decorative board 8 Sheet material for core layer 9 Decorative board

Claims (4)

[Claims] 1. A glass fiber non-woven fabric comprising a melamine resin and aluminum hydroxide, the composition ratio of which is 3 to 1
Two or more layers of core layer sheet material coated with a composition of 5 to 97% by weight to 97 to 85% by weight, and a woven glass fiber fabric inserted between these core layer sheet materials. A sheet material for a reinforcing layer coated with a thermosetting resin and a sheet material for a decorative layer are superimposed on the surface of the sheet material for the core layer, and are laminated and integrated. Decorative board. 2. The glass fiber woven fabric has a basis weight of 100 to 300.
decorative board according to claim 1 wherein the g / cm ^2. 3. The glass fiber nonwoven fabric has a basis weight of 30 to 150.
The decorative board according to claim 1, wherein the decorative board has a g / cm ² . 4. A sheet material for a decorative layer having a thickness of 0.5 mm
The decorative board according to claim 1, wherein the amount of the organic substance is 300 g / m ² or less.